ESAB Feed 3004 User manual

Brand: ESAB

Model: Feed 3004

Category: Welding System

Type: User manual

This manual is also suitable for

Valid for serial no. 745-xxx-xxxx, 910-xxx-xxxx0444 408 101 GB 20120830

Aristo Origo™

Feed 3004

Feed4804

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 Equipment 6................................................................

2.2 Control panel 6.............................................................

3 TECHNICAL DATA 7.................................................

4 INSTALLATION 8....................................................

4.1 Lifting instructions 8.........................................................

5 OPERATION 9.......................................................

5.1 Connections and control devices 10............................................

5.2 Water connection 11..........................................................

5.3 Wire feed pressure 11........................................................

5.4 Replacing and inserting Feed 3004 wire 11......................................

5.5 Replacing and inserting Feed 4804 wire 12......................................

5.6 Changing feed rollers on Feed 3004 12..........................................

5.7 Changing feed rollers on Feed 4804 12..........................................

6 MAINTENANCE 13....................................................

6.1 Inspection and cleaning 13....................................................

7 ORDERING SPARE PARTS 13.........................................

DIAGRAM 14............................................................

ORDER NUMBER 16.....................................................

WEAR PARTS 18........................................................

ACCESSORIES 22.......................................................

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be ob

served in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

 its operation

 location of emergency stops

 its function

 relevant safety precautions

 welding and cutting

2. The operator must ensure that:

 no unauthorised person is stationed within the working area of the equipment when it is

started up.

 no-one is unprotected when the arc is struck

3. The workplace must:

 be suitable for the purpose

 be free from drafts

4. Personal safety equipment

 Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

 Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

 Make sure the return cable is connected securely.

 Work on high voltage equipment may only be carried out by a qualified electrician.

 Appropriate fire extinquishing equipment must be clearly marked and close at hand.

 Lubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

 Install and earth the unit in accordance with applicable standards.

 Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

 Insulate yourself from earth and the workpiece.

 Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

 Keep your head out of the fumes.

 Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

 Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

 Protect bystanders with suitable screens or curtains.

FIRE HAZARD

 Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

 Protect your ears. Use earmuffs or other hearing protection.

 Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

Class A equipment is not intended for use in residential locations where

the electrical power is provided by the public low-voltage supply system.

There may be potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

This product is solely intended for arc welding.

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Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

The wire feed units Feed 3004 / Feed 4804 with control panel U6, MA23 or MA24

are intended for MIG/MAG welding together with 400A, 500A and 600A CAN

welding power sources.

The wire feed units contain four-wheel drive wire feed mechanisms as well as control

electronics.

They can be used together with wire on ESAB's MarathonPac, or on wire bobbin

(standard Ø 300 mm, accessory Ø 440 mm).

The wire feed unit can be installed either on the power source trolley, suspended above

the workplace, on a counter balance device or on the floor with or without wheel set.

ESAB's accessories for the product can be found on page 22.

2.1 Equipment

The wire feed unit is supplied with:

 instruction manual for the wire feed unit

 instruction manual in English for the control panel

Instruction manuals in other languages can be downloaded from the website,

www.esab.com.

 decal with recommended wear parts.

2.2 Control panel

The wire feed unit is supplied with one of the following control panels:

Empty panel for use with double wire feed units or with

use of control box U8

Knobs for setting the voltage and the wire feed speed /

current. Other parameters are controlled by

pushbuttons, with text in the display panel.

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MA23

Knobs for setting the voltage and the wire feed speed /

current. Other settings with push buttons.

MA24

Knobs for setting the voltage / QSet and the wire feed

speed / current. Other settings with push buttons.

See the separate instruction manual for a detailed description of the control panels.

3 TECHNICAL DATA

Feed 3004 Feed 4804

Mains voltage 42 V 50-60 Hz 42 V 50-60 Hz

Power requirement 336 VA 378 VA

Motor current I

max

8 A 9 A

Wire feed speed 0.8 - 25.0 m/min 0.8 - 25.0 m/min

Gun connection EURO EURO

Max. diameter wire bobbin 300 mm (*440 mm) 300 mm (*440 mm)

Wire dimension

Cored wire

0.8 - 1.6 mm

1.0 & 1.6 mm

0.9 - 1.6 mm

0.8 - 2.4 mm

1.0 & 2.4 mm

0.9 - 2.4 mm

Weight 15 kg 19 kg

Dimensions (l x w x h) 690 x 275 x 420 mm 690 x 275 x 420 mm

Operating temperature -10 to +40° C -10 to +40° C

Shielding gas

max pressure

All types intended for

MIG/MAG welding

0.5 MPa ( 5 bar)

All types intended for

MIG/MAG welding

0.5 MPa ( 5 bar)

Type of cooling

max pressure

50 % water /

50 % mono-ethylene glycol

0.5 MPa ( 5 bar)

50 % water /

50 % mono-ethylene glycol

0.5 MPa ( 5 bar)

Maximum permissible load at

60% duty cycle

100% duty cycle

630 A

500 A

630 A

500 A

Enclosure class IP23 IP23

* Accessories, see page 22.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at

a certain load without overloading. The duty cycle is valid for 40° C.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

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4 INSTALLATION

The installation must be carried out by a professional.

WARNING

When welding in an environment with increased electrical danger, only power

sources intended for this environment may be used. These power sources are

marked with the symbol

4.1 Lifting instructions

Order number for lifting eyelet can be found on page 22.

NOTE! If another mounting device is used, this must be electrically insulated from

the wire feed unit.

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5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

NOTE: When moving the equipment use intended handle. Never pull on the gun.

H 0935

WARNING

Assure that the side panels are closed during operation.

WARNING

To prevent the reel from sliding off the hub: Lock the

reel in place by turning the red knob as shown on the

warning label attached next to the hub.

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WARNING

Rotating parts can cause injury, take great care.

WARNING

There is a risk of tipping if the wire feed unit is fitted with a counterbalance arm.

Secure the equipment, especially if used on an uneven or sloping surface.

WARNING

Risk of crushing when replacing the wire bobbin!

Do not use safety gloves when inserting the welding wire between the feed rollers.

5.1 Connections and control devices

1 Control panel,

(see separate instruction manual)

6 Connection for welding current from power

source, (OKC)

Connection for remote control unit

Connection for U8

7 Connection for control cable from power

source or cooling unit

3 Connection BLUE, with ELP* for coolant to

the welding gun

8 Connection RED, for coolant to cooling

unit

4 Connection RED, for coolant from welding

gun

9 Connection for shielding gas

5 Connection for welding gun 10 Connection BLUE, for coolant from cooling

unit

NOTE! Display (digital instrument) and coolant connections only available on certain models.

* ELP = ESAB Logic Pump, see point 5.2.

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5.2 Water connection

The wire feed unit with water connection is equipped with a detection system ELP

(ESAB Logic Pump) which checks that the water hoses are connected. When

connecting a water-cooled welding gun, the water pump starts.

Detection only works with power sources that are equipped with ELP.

5.3 Wire feed pressure

Start by making sure that the wire moves smoothly through the wire guide. Then

set the pressure of the wire feeder's pressure rollers. It is important that the

pressure is not too great.

Fig 1 Fig 2

To check that the feed pressure is set correctly, you can feed out the wire against

an insulated object, e.g. a piece of wood.

When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed

rollers should slip.

If you hold the gun approx. 50 mm from the piece of wood, the wire should be

fed out and bend (fig. 2).

5.4 Replacing and inserting Feed 3004 wire

 Open the side panel.

 Disconnect the pressure sensor by folding it backwards, the pressure rollers

slide up.

 If necessary, roll back the wire and remove the wire bobbin.

 Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

 Make sure that the wire goes properly into the feed roller's track and into the

outflow nozzle or wire guide.

 Secure the pressure sensor.

 Close the side panel.

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5.5 Replacing and inserting Feed 4804 wire

 Open the side panel.

 Press down and pull the pressure device towards you and up.

 Pull out the bogie.

 If necessary, roll back the wire and remove the wire bobbin.

 Straighten out the new wire 10-20 cm. File away burrs and sharp edges from the

end of the wire before inserting it into the wire feed unit.

 Make sure that the wire goes properly into the feed roller's track and into the

outflow nozzle or wire guide.

 Reinstall the bogie.

 Close the side panel.

5.6 Changing feed rollers on Feed 3004

 Open the side panel

 Disconnect the pressure sensor (1) by folding it

backwards.

 Disconnect the pressure rollers (2) by turning the

axle (3) 1/4 turn clockwise and pulling out the axle.

The pressure rollers disconnect.

 Disconnect the feed rollers (4) by unscrewing the

nuts (5) and pulling out the rollers.

During installation, repeat the above in reverse order.

Choice of track in the feed rollers

Turn the feed roller with the dimensioning mark for the

required track towards you.

5.7 Changing feed rollers on Feed 4804

 Open the side panel.

 Press down and pull the pressure device (1) towards

you and up.

 Pull out the bogie (2).

 Undo the socket head cap screws (3) on the

holder for the intermediate nozzle and remove it.

 Undo the screw for the outflow nozzle (4) and

push back the nozzle.

 Completely undo the socket head cap screw

(5) in the centre.

 Undo the two outer socket head cap screws (6) 1/2 a

turn.

 Pull out the feed rollers (7).

During installation, repeat the above in reverse order.

Choice of track in the feed rollers

Place no, one or two driving washers

between the outer washer and the feed

roller. NOTE! When replacing the

pressure rollers (8), the entire bogie is

replaced.

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6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

6.1 Inspection and cleaning

Wire feed unit

Check regularly that the wire feed unit is not clogged with dirt.

 Cleaning and replacement of the wire feed unit mechanism's worn parts should

take place at regular intervals in order to achieve trouble-free wire feed. Note

that if pre-tensioning is set too hard, this can result in abnormal wear on the

pressure roller, feed roller and wire guide.

The brake hub

The hub is adjusted when delivered, if

readjustment is required, follow the instructions

below. Adjust the brake hub so that wire is slightly

slack when wire feed stops.

 Adjusting the braking torque:

 Turn the red handle to the locked position.

 Insert a screwdriver into the springs in the hub.

Turn the springs clockwise to reduce the braking torque

Turn the springs counter-clockwise to increase the braking torque. NB: Turn

both springs the same amount.

Welding gun

 The welding gun's wear parts should be cleaned and replaced at regular

intervals in order to achieve trouble-free wire feed. Blow the wire guide clean

regularly and clean the contact tip.

7 ORDERING SPARE PARTS

FEED 3004, Feed 4804 is designed and tested in accordance with the international and

European standards IEC/EN 60974-5 and IEC/EN 60974-10. It is the obligation of the

service unit which has carried out the service or repair work to make sure that the pro

duct still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

Diagram

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Feed 3004, Feed 4804

Order number

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Ordering no. Denomination Type

0460 526 881 Wire feed unit Aristo Feed 3004

0460 526 886 Wire feed unit Aristo Feed 3004, U6

0460 526 887 Wire feed unit Origo Feed 3004, MA23

0460 526 889 Wire feed unit Origo Feed 3004, MA24

0460 526 891 Wire feed unit with water Aristo Feed 3004

0460 526 896 Wire feed unit with water Aristo Feed 3004, U6

0460 526 897 Wire feed unit with water Origo Feed 3004, MA23

0460 526 899 Wire feed unit with water Origo Feed 3004, MA24

0460 526 991 Wire feed unit with water Aristo Feed 4804

0460 526 996 Wire feed unit with water Aristo Feed 4804, U6

0460 526 997 Wire feed unit with water Origo Feed 4804, MA23

0460 526 999 Wire feed unit with water Origo Feed 4804, MA24

0459 839 017 Spare parts list Feed 3004, Feed 4804

0460 454 Instruction manual Origo MA23, Origo MA24

0459 287 Instruction manual Aristo U6

0459 310 Instruction manual Aristo U8

Technical documentation is available on the Internet at www.esab.com

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Feed 3004

Wear parts

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Item Ordering no. Denomination Notes Wire type Wire dimensions

HI1 0455 072 002

0456 615 001

Intermediate nozzle

Fe, Ss & cored

HI2 0469 837 880

0469 837 881

Outlet nozzle

Fe, Ss & cored

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 0.8-1.6 mm

HI3 0191 496 114 Key

HI4 0215 701 007 Locking washer

HI5a 0459 440 001 Motor gear euro Drive gear

Item Ordering no. Denomination Wire type Wire dimensions Groove

typ

Roller

markings

HI5b 0459 052 001 Feed/pressure rollers Fe, Ss & cored Ø 0.6 & 0.8 mm V 0.6 S2 & 0.8 S2

0459 052 002 Feed/pressure rollers Fe, Ss & cored Ø 0.8 & 1,0 mm V

0.8 S2 & 1.0 S2

0459 052 003 Feed/pressure rollers Fe, Ss & cored Ø 0.9/1.0 & 1.2 mm V 1.0 S2 & 1.2 S2

0459 052 013 Feed/pressure rollers Fe, Ss & cored Ø 1.4 & 1.6 mm V 1.4 S2 & 1.6 S2

0458 825 001 Feed/pressure rollers Cored Ø 0.9/1.0 & 1.2 mm V-Knurled 1.0 R2 & 1.2 R2

0458 825 010 Feed/pressure rollers Cored Ø 1.2/1.2 mm V-Knurled 1.2 R2 & 1.2 R2

0458 825 002 Feed/pressure rollers Cored Ø 1.2 & 1.4 mm V-Knurled 1.2 R2 & 1.4 R2

0458 825 003 Feed/pressure rollers Cored Ø 1.6 mm V-Knurled 1.6 R2 & 2.0 R2

0458 824 001 Feed/pressure rollers Al Ø 0.8 & 0.9/1.0 mm U 0.8 A2 & 1.0 A2

0458 824 002 Feed/pressure rollers Al Ø 1.0 & 1.2 mm U 1.0 A2 & 1.2 A2

0458 824 003 Feed/pressure rollers Al Ø 1.2 & 1.6 mm U 1.2 A2 & 1.6 A2

Use only pressure and feed rollers marked A2, R2 or S2.

The rollers are marked with wire dimension in mm, some are also marked with inch.

Item Ordering no. Denomination Notes

HI6 Washer Ø 16/5x1

HI7 Screw M4x12

HI8 Screw M6x12

HI9 Washer Ø 16/8.4x1.5

HI10 0469 838 001 Cover

HI11 0458 722 880 Axle and Nut

HI12 0459 441 880 Gear adapter

HI13 0455 049 001 Inlet nozzle Ø 3mm for 0.6-1.6mm Fe, Ss, Al and cored wire

HI14 0458 999 001 Shaft

HI15 Nut M10

HI16 0458 748 002 Insulating washer

HI17 0458 748 001 Insulating bushing

Item Ordering no. Denomination Wire type Wire dimensions

HI18 0156 602 001 Inlet nozzle Fe, Ss, Al & Cored Ø 2 mm plastic for 0.6-1.6 mm

Welding with aluminium wire

In order to weld with aluminium wire, proper rollers, nozzles and liners for aluminium wire MUST be

used, It is recommended to use 3 m long welding gun for aluminium wire, equipped with appropriate

wear parts.

Feed 3004

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Feed 4804

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Item Ordering no. Denomination Wire type Wire dimensions

HK1 0469 837 880

0469 837 881

0469 837 882

Outlet nozzle

Fe, Ss & cored

Ø 2.0 mm steel for 0.6-1.6 mm

Ø 2.0 mm plastic for 1.0-1.6 mm

Ø 3.4 mm steel for 2.0-2.4 mm

Item Ordering no. Denomination Wire type Wire Ø

Groove 1 Groove 2 Groove 3 Groove

typ

Roller /

Bogey

mark

ings

HK2 0366 966 880 Feed Roller Fe, Ss & cored 0.6-1.2 0.6-0.8 0.9-1.0 1.2 V 1

0366 966 888 Feed Roller Fe, Ss & cored 0.9 0.9 0.9 0.9 V .035

0366 966 881 Feed Roller Fe, Ss & cored 1.4-1.6 1.4-1.6 2.0 2.4 V 2

0366 966 889 Feed Roller Fe, Ss & cored 1.2 .045” / 1.2 .045” / 1.2 .045” / 1.2 V .045 / 7

0366 966 890 Feed Roller Fe, Ss & cored 1.6 1.6 1.6 1.6 V 1/16

0366 966 900 Feed Roller Fe, Ss & cored 0.9-1.6 0.9-1.0 1.2 1.4-1.6 V 6

0366 966 893 Feed Roller Cored 1.2 1.2 1.2 1.2 V-Knurled .045

0366 966 882 Feed Roller Cored 1.2-2.0 1.2 1.4-1.6 2.0 V-Knurled 3

0366 966 882 Feed Roller Cored 1.6 1.6 1.6 1.6 V-Knurled 1/16

0366 966 883 Feed Roller Cored 2.4 2.4 not used not used V-Knurled 4

0366 966 885 Feed Roller Al 1.2 1.2 1.2 1.2 U U2

0366 966 899 Feed Roller Al 1.0-1.6 1.0 1.2 1.6 U U4

Item Ordering no. Denomination Notes

HK3 0156 707 001 Distance washer

HK4 0156 707 002 Adjustment spacer

HK5 Screw M5x20

HK6 Screw M5x16

HD = Heavy Duty

Item Ordering no. Denomination Wire type Wire dimensions Groove

typ

Roller /

Bogey

markings

HK7 0366 902 880 Bogey (HD) Fe, Ss & cored Ø 0.6 - 1.2 mm V 1

0366 902 902 Bogey (HD) Fe, Ss & cored Ø 0.9 mm V .035

0366 902 900 Bogey (HD) Fe, Ss & cored Ø 0.9 - 1.6 mm V 6

0366 902 881 Bogey (HD) Fe, Ss & cored Ø 1.4 - 2.4 mm V

0366 902 894 Bogey (HD) Fe, Ss & cored Ø 1.2 mm V .045 / 7

0366 902 901 Bogey (HD) Fe, Ss & cored Ø 1.6 mm V 1/16

0366 902 903 Bogey (HD) Cored Ø 1.2 mm V-Knurled .045

0366 902 882 Bogey (HD) Cored Ø 1.2 - 2.0 mm V-Knurled 3

0366 902 883 Bogey (HD) Cored Ø 2.4 mm V-Knurled 4

0366 902 904 Bogey (HD) Cored Ø 1.6 mm V-Knurled 1/16

0366 902 899 Bogey (HD) Al Ø 1.0 - 1.6 mm U U4

0366 902 886 Bogey (HD) Al Ø 1.2 mm x 3 U -

Item Ordering no. Denomination Wire type Wire dimensions

HK8 0366 944 001 Washer

HK9 0156 603 001

0156 603 002

0332 322 001

0332 322 002

Intermediate nozzle

Fe, Ss & Al

Cored

Ø 2 mm plastic for 0.6-1.6 mm

Ø 4 mm plastic for 2.0-2.4 mm

Ø 2.4 mm copper for 1.2-2.0 mm

Ø 4 mm copper for 2.4 mm

Item Ordering no. Denomination Note

HK10 0215 702 708 Locking washer

HK11 Nut M10

HK12 0458 748 002 Insulating washer

HK13 0458 748 001 Insulating bushing

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ESAB Feed 3004 User manual

Brand: ESAB

Model: Feed 3004

Category: Welding System

Type: User manual

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ESAB Feed 3004 User manual

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